AEROMOTIVE Part # 14129 99-04 C5 Corvette Fuel Rail / Regulator Kit INSTALLATION INSTRUCTIONS CAUTION: Installation of this product requires detailed knowledge of automotive systems and repair procedures. We recommend that this installation be carried out by a qualified automotive technician. Installation of this product requires handling of gasoline. Ensure you are working in a well ventilated area with an approved fire extinguisher nearby. Extinguish all open flames, prohibit smoking and eliminate all sources of ignition in the area of the vehicle before proceeding with the installation. When installing this product, wear eye goggles and other safety apparel as needed to protect yourself from debris and sprayed gasoline.

WARNING! The fuel system is under pressure. Do not open the fuel system until the pressure has been relieved. Refer to the appropriate vehicle service manual for the procedure and precautions for relieving the fuel system pressure. The enclosed Aeromotive fuel rails utilize o-ring sealed AN-08 style ports; these ports are NOT PIPE THREAD and utilize NO THREAD SEALANT. To use the enclosed fuel rails in your vehicle’s fuel system you must install the necessary adapter fittings and o-rings, high pressure fuel lines and regulator to adapt your system to the configuration and ports of these fuel rails. Please call for a catalog of the complete line of quality Aeromotive products. The enclosed Aeromotive fuel rails are intended to be installed on an unmodified OEM intake manifold of the identified application. Aeromotive cannot guarantee the proper fitment on aftermarket intake manifolds and the end user is responsible for verifying proper fitment and assumes all liability. When installing o-rings it is important to place a small amount of light oil on both the o-ring and the mating surface to ease installation and prevent damaging the o-ring. The following installation instructions are for a typical installation, for specific year and model installation instructions please refer to your vehicles service manual. Aeromotive system components are not legal for sale or use on emission controlled motor vehicles.

Special tools needed: Fuel supply line quick disconnect tool

Supplies needed: Vehicle service manual Fuel injector replacement O-rings Light oil Solvent parts cleaner Clean shop towels

This kit contains the following parts: 1ea p/n 14106 LS1 Fuel Rails 1ea p/n 15116 Supply Adapter Tee Fitting 1ea p/n 15103 Return Adapter Fitting 1ea p/n 13101 A1000 Injected Bypass Regulator 2ea p/n 15607 ORB-08/AN-08AN Port Fitting 2ea p/n 15610 ORB-10/AN-08AN Port Fitting 1ea p/n 15606 ORB-06/AN-06AN Port Fitting 1ea p/n 15650 AN–06 Straight Hose End 1ea p/n 15652 AN–06 90-Deg Hose End

1ea p/n 15654 AN–08 45-Deg Hose End 5ea p/n 15655 AN-08 90-Deg Hose End 2ea p/n 15665 AN–08 90-Deg Male ORB Hose End 8ft AN–06 Stainless Steel Braided Fuel Line 10ft AN–08 Stainless Steel Braided Fuel Line 1ea ORB-06 O-Ring 4ea ORB-08 O-Ring 2ea ORB-10 O-Ring

This System requires the use of an OEM replacement fuel filter from a ‘97-’98 Corvette, GM#10287788, ACDelco #GF820, Wix #33529, Fram #G7740 or equiv. This filter is NOT included with the kit. The following steps are typical of most installations: 1. Once the engine has been allowed to cool, disconnect the negative battery cable and relieve fuel system pressure, referring to the appropriate vehicle service manual for the procedure on doing so. 2. Remove the air intake ducting from the throttle body and position it out of the way. 3. Note the location of and remove any vacuum lines connected to the upper intake manifold and position them out of the way. 4. Check for any dirt or debris around the fuel injectors. If any is evident, wash it off with some solvent parts cleaner or wipe it off with a clean shop towel. 5. Disconnect the electrical connector at each injector, making note of the location of each. 6. Carefully relieve fuel system pressure per factory service manual. 7. Disconnect the supply and return fuel line from the OEM fuel rails. These lines are attached by a special quick disconnect fitting which requires a special tool for removal. Place clean shop towels around the open fuel lines to catch any gasoline that may drip out and to prevent any dirt from entering the fuel lines. Failure to satisfy all safety considerations will result in fire, explosion, injury and/or loss of life to yourself and/or others. 8. Remove the bolts that attach the fuel rail to the lower intake (Typically there are 4 of them). 9. Place clean shop towels around the injectors to catch any gasoline that may be spilled during their removal. Remove the injectors from the manifold by gently pulling upward on the fuel rail / injector assembly. Keep all injectors connected to the fuel rails. If an injector does pull out of the fuel rail, it may spill a large amount of fuel. Failure to satisfy all safety considerations will result in fire, explosion, injury and/or loss of life to yourself and/or others.

10. Carefully remove the fuel injectors from the OEM fuel rail. 11. Remove the old o-rings from the fuel injectors, inspect the injectors for any dirt or debris and clean if needed. It is suggested that the old o-rings be replaced, contact your local parts store or dealer to purchase the correct replacement o-rings. 12. Carefully install the new injector o-rings on the injectors. When installing o-rings it is important to place a small amount of light oil on both the o-ring and the mating surface to ease installation and prevent damaging the o-ring. 13. Place a thin coat of light oil in the fuel rail injector bores and in the lower intake manifold injector bores to help prevent cutting the o-rings during installation. 14. Carefully place each of the fuel injectors in the corresponding fuel injector bore of the Aeromotive fuel rails. 15. Place each of the fuel rail / injector assemblies onto the lower intake manifold, ease the fuel injectors into the injector bores in the lower intake being careful that the injector does not dislodge itself from the fuel rail. 16. Reinstall the rail mounting bolts and tighten 17. With the Aeromotive fuel rail properly secured to the intake manifold, Move the fuel injector vertically downward until it bottoms out on the intake manifold, In this downward position, inspect the upper fuel injector o-ring (on the fuel rail side) and insure it is fully covered by the fuel rail injector bore. If any of the o-ring is exposed, loosen the fuel rail bracket screws and adjust the installation height unit the oring is no longer exposed and retighten the bracket screws. In the situation where the fuel injector has no vertical travel, either the fuel rail brackets can be adjusted or the brackets shimmed until the fuel injector fits freely. Do not pressurize the fuel rail until the proper fuel rail installation height is achieved. 18. Find suitable place in the vehicle’s engine compartment to mount the Aeromotive regulator, typically on or near the strut tower. Using the supplied mounting bracket as a template, mark the bracket mounting holes and drill to accept a #10 screw. 19. With the bracket attached to the regulator, mount the bracket and regulator to the vehicle using two #10 screws, nuts and lock washers. 20. Install one ORB-10 o-ring on the port (cut-off) side of each of the two of the P/N 15608 ORB-10/AN-8 port fittings and one ORB-06 o-ring on the port (cut-off) side of P/N 15606 ORB-06/AN-06 port fitting. 21. Thread the port (o-ring) side of the P/N 15608 port fitting into each of the two AN-10 ports on the regulator. Also, thread the port (o-ring) side of the P/N 15606 fitting into the bottom of the regulator.

22. Install one ORB-08 o-ring on the port (cut-off) side of each of the four P/N 15607 ORB-08/AN-08 port fittings.

23. Install one ORB-08 o-ring on each of the two p/n 15665 AN-8 90-degree male ORB hose ends.

24. Thread the o-ring side of each two ORB-08/AN-08 port fittings in the front of each fuel rail.

25. Inspect the OEM fuel supply line o-rings in the female quick connect and replace if necessary. Place a light coat of oil on the fuel supply line o-rings and the supply line adapter fitting to ease installation. Connect the male quick-connect side of the p/n 15116 supply tee adapter fitting to the female quick connect on the OEM fuel supply line. 26. Using the image of a Typical Finished Configuration below as a reference, connect one AN-08 90degree hose end to the front of each fuel rail. Connect one AN-08 45-degree hose end to the passenger side of the fuel pressure sensor adapter and connect one AN-08 90-degree hose end to the driver side of the fuel pressure sensor adapter. 27. Plan a route for each of the two lines between the fuel supply tee adapter and the fuel rails, measure the two lengths of fuel line needed, and cut. See section titled Hose and Fitting Assembly for fuel line assembly instructions. Once the hoses are assembled, ensure there is no debris in the hose and install them.

28. Connect one AN-08 90-Degree Male ORB hose end to the rear of each fuel rail. Connect one AN-08 90-Degree Hose End to the inlet ports on each side of the p/n 13101 regulator. Plan a route for each of the two lines between the fuel pressure regulator and the fuel rails, measure the two lengths of fuel line needed and cut. See section titled Hose and Fitting Assembly for fuel line assembly instructions. Once the hoses are assembled, ensure there is no debris in the hose and install them.

29. Locate the OEM fuel filter/regulator and remove it, then replace it with a fuel filter only from a ‘97-’98 Corvette. Suitable filter only p/n’s include GM#10287788, ACDelco #GF820, Wix #33529, Fram #G7740 or equiv. (not included in kit). On the 5/16” quick- connect for the OEM return line that the new fuel filter has no prevision for, Install the included OEM Fuel line adapter p/n15103. Please note if installing a high performance fuel pump, (Similar to Aeromotive P/N 11101) the OEM return line may be too restrictive to handle the volume of fuel that these pumps are capable of pumping. To prevent losing lower pressure adjustability of your regulator, it may be necessary to replace the OEM return line with a 3/8” ID (AN-06) return line in these cases.

30. Connect one AN-06 90-degree hose end to the return port on bottom of the p/n 13101 fuel pressure regulator. Connect one AN-06 straight hose end on the p/n 15103 OEM fuel line adapter. Plan a route for the line between the regulator and the adapter, measure the length of AN-06 fuel line needed and cut. See section titled Hose and Fitting Assembly for fuel line assembly instructions. Once the hose is assembled, ensure there is no debris in the hose and install it.

Typical Finished Configuration 31. Reassemble the vehicle using the reverse of the foregoing removal procedure. 32. Remove the 1/8 NPT pipe plug from the fuel supply adapter tee fitting or the fuel pressure regulator and attach a suitable fuel pressure gauge. Ensure that any spilled gasoline and any gasoline soaked shop towels are cleaned up and removed from the vicinity of the vehicle! 33. Reconnect the battery and turn the ignition to the ON position WITHOUT starting the car. After several seconds, check the fuel pressure. If there is no fuel pressure, turn the ignition key to the OFF position, wait one minute, return the ignition to the ON position, and recheck the fuel pressure. Repeat this ignition OFF and ON procedure until the fuel pressure gauge registers fuel pressure. With the fuel pressure gauge registering fuel system pressure, check for fuel leaks from and around the Aeromotive fuel pressure regulator, fuel rails, all fuel lines and connections! If any fuel leaks are found, turn the ignition key to the OFF position, remove any spilled fuel and repair the leak before proceeding! 34. Adjust the fuel pressure regulator to the desired fuel pressure. Once the fuel pressure gauge registers the desired fuel system pressure and there are no fuel leaks, start the engine. 35. Turn off the engine and allow it to cool. If you do not want to keep the fuel pressure gauge on the vehicle, relieve the fuel system pressure as instructed in the appropriate vehicle service manual. Remove the fuel pressure gauge and reinstall the 1/8 NPT pipe plug, using thread sealant. 36. Test drive the car to insure proper operation and re-check the fuel system for leaks. If any leaks are found, immediately shutoff the engine and repair the leak(s)!

Hose and Fitting Assembly CAUTION: When assembling this product, wear eye goggles and other safety apparel as needed to protect yourself from debris and sharp edges. A. Wrap hose with masking tape at desired cutoff length. Cut hose through masking tape squarely to desired length using a cut-off machine or a fine tooth hacksaw. Remove the masking tape. B. Unthread the hose socket from the rest of the hose end fitting.

C. Insert hose in the socket with a twisting and pushing motion until the hose is fully seated in the socket. D. Using a grease pencil, marker or tape, mark the location of the hose in relation to the hose socket

which you just installed. E. Using a light oil lubricate the inside of the hose and the hose end mating parts.

F. Carefully thread the hose end onto the hose socket, making sure that the hose does not push out of socket, by observing the mark you placed on the hose in step D.

G. Using a properly sized wrench, complete threading the two components together (The maximum allowable gap between the two fitting components is .030 inches).

H. Inspect the hose for push out by comparing the mark you made on the hose in step D to the hose end socket location. I.

Clean all debris from exterior and interior of hose.

J.

All lines should be tested to twice their operation pressure prior to use.

Thanks for purchasing another quality product designed, engineered and manufactured in Kansas City, USA!

AEROMOTIVE, INC. 7805 Barton Street, Lenexa, KS 66214 913-647-7300 fax 913-647-7207 www.aeromotiveinc.com

AEROMOTIVE, INC. LIMITED WARRANTY This Aeromotive Product, with proof of purchase dated on or after January 1, 2003, is warranted to be free from defects in materials and workmanship for a period of one year from the original date of purchase. No warranty claim will be valid without authentic, dated proof of purchase. This warranty is to the original retail purchaser and none other and is available directly from Aeromotive and not through any point of distribution or purchase. If a defect is suspected, the retail purchaser must contact Aeromotive directly to discuss the problem, possible solutions and obtain a Return Goods Authorization (RGA), if deemed necessary by the company. Please call 913-647-7300 and dial option 3 for the technical service dept. All returns must be shipped freight pre-paid to the company and with valid RGA before they will be processed. Aeromotive will examine any product returned with the proper authorization to determine if the failure resulted from a defect or from abuse, improper installation, misapplication or alteration. Aeromotive will then, at it’s sole discretion, return, repair or replace the product. If any Aeromotive product is determined defective, buyer’s exclusive remedy is limited in value to the sale price of the good. In no event shall Aeromotive be liable for incidental or consequential damages. Aeromotive expressly retains the right to make changes and improvements in any product it manufactures and sells at any time. These changes and improvements may be made without notice at any time and without any obligation to change the catalogs or printed materials. Aeromotive expressly retains the right to discontinue at any time and without notice any Aeromotive product that it manufactures or sells. This warranty is limited and expressly limits any implied warranty to one year from the date of the original retail purchase on all Aeromotive products. No person, party or corporate entity other than Aeromotive shall have the right to: determine whether or not this Limited Warranty is applicable to any Aeromotive product, authorize any action whatsoever under the terms and conditions of this Limited Warranty, assume any obligation or liability of any nature whatsoever on behalf of Aeromotive under the terms and conditions of this Limited Warranty. This Limited Warranty covers only the product itself and not the cost of installation or removal. This Limited Warranty is in lieu of and expressly excludes any and all other warranties, expressed or implied. This Limited Warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Aeromotive, Inc. 7805 Barton Street, Lenexa, KS 66214 Phone: (913) 647-7300 Fax: (913) 647-7207